Multivariate Analysis of Variables Affecting Thermal Performance of Black Liquor Evaporators
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1 Multivariate Analysis of Variables Affecting Thermal Performance of Black Liquor Evaporators Hamideh Hajiha & Honghi Tran (University of Toronto) Odessa Websdale, Denys Holik & Bill Downing (DMI) 1
2 Thermal Performance of Evaporators Related to scaling Scaling can be costly Figure: Heavy scale built up around the 58% flash tank outlet vortex breaker leading to an unscheduled shutdown of the evaporator system for scale removal 2
3 Kraft Recovery Process Lime Kiln Wood Pulping Digester Lime Mud White Liquor Lime Causticizing Plant Pulp Washing Weak Black Liquor 15% solids Evaporators Green Water Liquor Recovery Smelt Boiler Heavy Black Liquor 70% solids 3
4 Potential Factors Affecting Thermal Performance of Evaporators Equipment Operation Black liquor property 4
5 Objective To determine correlations between thermal performance and operating conditions of black liquor evaporators using multivariate data analysis techniques 5
6 Approach Mill visit and data collection Multivariate data analysis: Study many interconnected parameters simultaneously Study correlations that may exist among parameters 6
7 Evaporators at DMI 5 effect Falling Film Evaporators 467 ton/hr WBL at 13.5% solids and 85 C 109 ton/hr SBL at 58% solids and 115 C 7
8 Evaporation System at DMI Steam Primary Reflux condenser TW Cond. CW MW SC HSC WBL FT WW 70% ST 70% FT 58% ST 58% FT #2 FT Soap Skimmer Tank Secondary Reflux condenser Black Liquor Flow Steam Flow Water Flow 8
9 Scaling at DMI 9
10 MVDA Variables 98 Input Variables 42 related to black liquor 22 related to steam 23 related to the mill operation 11 related to liquor chemistry 4 Output Variables Heat transfer coefficient 58% flash tank level 58% flash tank discharge temperature 58% storage tank vent temperature U = Q AΔT = W evap λ + ( T T ) ( T BPR) A T o Sat W WL Cond. Cp WL o i 10
11 MVDA Techniques (PCA) The first Principal Component (PC) models the direction of largest variation in the data TTA PC #1 BL Solids Steam Flowrate 11
12 MVDA Techniques TTA PC #1 BL Solids PC #2 Steam Flowrate 12
13 Partial Least Squares Regression (PLS) Inputs Outputs Day 1 Steam Flowrate TTA BL Solids Day 1 Heat Transfer Coeff. 58% FT Discharge Temp 58% FT Level Day 2 Day 2 Day 3 Day 3 13
14 Scatter Plot t[2] t[2] I /01/ /01/ /01/ IV II III t[1] % Confidence Interval t[1] 14
15 Loading plot I 3 rd effect recirc. pump load Wash residual EA HSC boiling point rise II Steam pressure to HSC heaters Clean condensate conductivity 70% Storage tank level IV 70% FT vapor pressure WBL flow to FT Steam pressure to evaps Steam flow to 1 st effect III 15
16 Scatter and Loading Plot Quad II - Higher: Steam P, T, flow to HSC HSC boiling point rise Product BL % solids Quad III - Higher: Steam P, T, flow to evaporators WBL flow to flash tank Evaporation across effects 16
17 Coefficient Plot 17 Heat Transfer Coeff. WBL Flow to WBL Flash Tank WBL % Solids to WBL Flash Tank 4th Effect Recirc. Pump Load Steam Flow to 1st Effect Steam Temp to 1st Effect Steam Pressure to Evaporators Manual Valve Steam to 1st Effect 1st Effect Boiling Point Rise Evaporation across Effects Cooling Water Flow to SC Tempering Water Flow to SC Mill Water Temp to SC Warm Water Temp from SC 2nd Effect Transfer Pump Load 70% BL Storage Tank #2 Level
18 Heat Transfer Coefficient WBL % SOLIDS TO FLASH TANK STEAM PRESSURE TO EVAPS 0-2 TOTAL WATER EVAPORATED ACROSS EFFECTS COOLING WATER FLOW TO SC WBL FLOW TO FLASH TANK -4 18
19 58% Flash Tank Level TEMPERING WATER FLOW TO SC STEAM PRESSURE TO EVAPS MILL WATER TEMP TO SC WASH RESIDUAL EA
20 58% Flash Tank Discharge Temp 4 2 TEMPERING WATER FLOW TO SC 0 #4 EFFECT RECIRC. PUMP LOAD #2 EFFECT TRANSFER PUMP LOAD -2 20
21 58% Storage Tank Vent Temp TEMPERING WATER FLOW TO SC WBL FLOW TO FLASH TANK COOLING WATER FLOW TO SC
22 Variables U 58% FT Level 58% FT Dis. Temp 58% ST Vent Temp Tempering Water Flow to SC WBL % Solids to F.T Cooling Water Flow to SC Steam Pressure to Evaporators WBL Flow to F.T SC=Surface Condenser, FT=Flash Tank, ST=Storage Tank, Dis.=Discharge 22
23 Overall Heat Transfer Coefficient U (KJ/m 2 hr-c) /1/07 1/4/07 30/6/07 28/9/07 27/12/07 Date 23
24 Chipmeter Speed WBL Storage Tank #1 WBL Storage Tank #2 WBL Flow to Flash Tank WBL % Solids to Flash Tank BL Mass Flow to Evaporators WBL Temperature to 5th Effect 5th Effect Recirc. Temperature 4th Effect Recirc. Temperature 2nd Effect Recirc. Temperature 3rd Effect Recirc. Temperature 1st Effect Recirc. Temperature 5th Effect Level 2nd Effect Level 5th Effect Recirc. Pump Load 4th Effect Recirc. Pump Load 2nd Effect Recirc. Pump Load 3rd Effect Recirc. Pump Load 1st Effect Recirc. Pump Load Steam Flow to 1st Effect Steam Temperature to 1st Effect Steam Pressure to Evaporators Manual Valve Steam to 1st Effect 1st Effect Vapour Pressure 2nd Effect Vapour Pressure 3rd Effect Vapour Pressure 4th Effect Vapour Pressure 5th Effect Vapour Pressure Surface Condenser Pressure 1st Effect Boiling Point Rise Evaporation across Effects Cooling Water Flow to SC Tempering Water Flow to SC Mill Water Temperature to SC Warm Water Temp. from SC Clean Condensate Conductivity Combined Condensate Conductivity Foul condensate Conductivity 2nd Effect Flash Tank Level SBL Temp. -Soap Skimmer Tank 2nd Effect Transfer Pump Load Soap Skimmer Tank Level 58% BL Storage Tank Level BL Flow to HSC SBL % Solids BL Temp. to N. HSC Heater BL Temp. to S. HSC Heater BL Temp. from N. HSC Heater BL Temp. from S. HSC Heater HSC Pressure HSC Boiling Point Rise Steam Flow to HSC Heaters Steam Temp. to HSC Heaters Steam Pressure to HSC De-SH Control Valve Steam to HSC Heaters Manual Valve Steam to HSC Heaters N. HSC Steam Mass Flow S. HSC Steam Mass Flow Evaporation across HSC 70% BL Storage Tank Temperature 70% Flash Tank Vapour Pressure Product BL % Solids 70% BL Storage Tank #1 Level 70% BL Storage Tank #2 Level 1100 KPa Steam Flow to Ejectors 400 KPa Steam Flow to Stripper Condensate Stripper Temperature Stripped Condensate to Recaust Mill Water to Trim Condenser Temp % Causticity EA-to-Wood Species into Chipmeter MCC EA Wash Residual EA KAPPA # Comparison of Contribution Plots Vapor pressure in effects Low U Period High U Period
25 High vs. Low U Periods: Higher U periods had: a lower WBL % solids to FT, and recirculation pump load a higher steam temperature, pressure and flow rate to the 1st effect a higher WBL Temp, and flow rate a higher cooling water flow rate to SC a higher vapour pressure in effects 25
26 Conclusion The water flow rate to the surface condenser, the weak black liquor % solids, and the weak black liquor flow rate to the evaporators were found to be the dominant parameters in the PLS model of the evaporators based on the loading plot and VIP plot 26
27 Acknowledgements Members of Increasing Energy and Chemical Recovery Efficiency in the Kraft Process Abitibi-Bowater Alstom Power Andritz Aracruz Celulose Babcock & Wilcox Boise Paper Solutions Carter Holt Harvey Cenibra Clyde-Bergemann DMI Peace River Pulp Diamond Power International Domtar Georgia Pacific International Paper Irving Pulp & Paper Metso Power MeadWestvaco Stora-Enso Research Tembec Votorantim Celulose E Papel NSERC 27
28 Thank You 28
29 Scatter Plot t(2) t(1) 29
30 Contribution Plot for the Outlier 5 th effect vapour pressure 58% BL Storage Tank Vent Temperature KAPPA # (To-Ti)liquor 1st Effect Recirculation Temp. in kelvin Latent Heat of Water Out CPwl Q- Total Heat Transferred in Evaps delta T U- Overall Heat Transfer Coefficient Wevap/Chipmeter Speed U/Chipmeter Speed Production Rate Chipmeter Speed WBL Storage Tank #1 T N R WBL Storage Tank #2 WBL Flow to Flash Tank WBL % Solids to Flash Tank Mass Flow BL Solids to Evaporators WBL Temperature to 5th Effect 5th Effect Recirculation Temperature 4th Effect Recirculation Temperature 2nd Effect Recirculation Temperature 3rd Effect Recirculation Temperature 1st Effect Recirculation Temperature 5th Effect Level 4th Effect Level 2nd Effect Level 3rd Effect Level 1st Effect Level 5th Effect Recirculation Pump Load 4th Effect Recirculation Pump Load 2nd Effect Recirculation Pump Load 3rd Effect Recirculation Pump Load 1st Effect Recirculation Pump Load Steam Flow to 1st Effect Steam Temperature to 1st Effect Steam Pressure to Evaporators Control Valve Steam to 1st Effect Manual Valve Steam to 1st Effect 1st Effect Vapour Pressure 2nd Effect Vapour Pressure 3rd Effect Vapour Pressure 4th Effect Vapour Pressure 5th Effect Vapour Pressure Surface Condenser Pressure 1st Effect Boiling Point Rise Evaporation Across Effects Steam Economy Across Effects Cooling Water Flow to SC Tempering Water Flow to SC Mill Water Temperature to SC Warm Water Temperature from SC Clean Condensate Conductivity Combined Condensate Conductivity Foul condensate Conductivity 2nd Effect Flash Tank Level SBL Temp. Soap Skimmer Tank 2nd Effect Transfer Pump Load Soap Skimmer Tank Level Skimmed Liquor Pump Load 58% BL Storage Tank Level 58% Flash Tank Level 58% Flash Tank Discharge Temperature BL Flow to HSC Saltcake Addition SBL % Solids BL Temperature Into N. HSC Heater BL Temperature Into S. HSC Heater BL Temperature Out of N. HSC Heater BL Temperature Out of S. HSC Heater HSC Pressure HSC Boiling Point Rise Steam Flow to HSC Heaters Steam Temperature to HSC Heaters Steam Pressure to HSC Desuperheater Control Valve Steam to HSC Heaters Manual Valve Steam to HSC Heaters Evaporation N. HSC Stem Mass Flow Evaporation S. HSC Stem Mass Flow Evaporation Across HSC Steam Economy Across Effects & HSC 70% BL Storage Tank Temperature 70% Flash Tank Vapour Pressure 70% Flash Tank Level Product BL % Solids 70% BL Storage Tank #1 Level 70% BL Storage Tank #2 Level 1100 KPa Steam Flow to Ejectors 400 KPa Steam Flow to Stripper Foul Condensate Flow to Stripper Preheater Foul Condensate Temp. to Stripper Preheater Condensate Stripper Level Condensate Temp. Stripper Upper Section Condensate Temp. Stripper Lower Section Stripped Condensate to Recaust Mill Water to Trim Condenser Temp Warm Water Temperature to Trim Condenser NCG Pressure from Trim Condenser %Casuticity Green Liquor Reduction Total Titratable Alkali Caustic Flow to White Liquor Storage Tank EA-to-Wood Species into Chipmeter Extraction Residual from Digester MCC EA Wash Residual EA W C E L E E E EE C U 2 nd effect recirculation temp 30
31 Loading Plot 0.2 I HSC BOILING POINT RISE PRODUCT BL % SOLIDS EVAPORATION EVAPORATION NORTH HSC STEAM MASS FLOW STEAM FLOW SOUTH TO HSC HSC HEATER STEAM MASS FLOW SPECIES INTO CHIPMETER II EVAPORA CONTROL TION ACROSS VALVE HSC STEAM TO HSC HEATERS STEAM STEAM TEMP PRESSURE - HSC -HSC HEATERS HEATERS DES MANUAL VALVE STEAM-HSC HEATERS p[2] #3 EFFECT RECIRC PUMP LOAD#5 EFFECT RECIRC PUMP LOAD 70% BL STORAGE TEMP BL TEMP OUTLT-N.HSC H BL TEMP OUTLT-S.HSC H #2 EFFECT RECIRC PUMP LOAD WASH RESIDUAL EA WARM WATER TEMP FROM SURFACE CONDENSER BL TEMP INLET-S.HSC INLET-N.HSC #5 EFFECT VAPOUR PRESSURE #4 EFFECT TEMP RECIRC CONDENSATE PUMP LOADSTRIPPER LOWER SECTION #5 EFFECT RECIRCULATION TEMP #2 EFF FLASH TANK LEVEL CLEAN CONDENSATE CONDUCTIVITY TO COLLECT WBL % SOLIDS - WEAK LIQR FLASH TANK %CAUSTICITY (CE) COOLING WATER FLOW TO SURFACE CONDENSER #1 EFF SURFACE 1100 BOILING KPA CONDENSER STEAM POINT FLOW RISE #2 EFFECT PRESSURE TO SOAP EJECTORS SKIMMER TANK LEVEL LEVEL MILL 400 WATER KPA TEMP STEAM TO FLOW SURFACE TO STRIP CONDENSER BL FLOW TO HSC #4 EFFECT RECIRCULATION TEMP FOUL CONDENSATE FROM SEAL TANK WBL TEMP -#5 EFFECT WBL STORAGE TNK#2 MILL WATER TO TRIM CONDENSER TEMP #2 EFFECT RECIR #1 EFFECT RECIRCULATIO #3 #1 HSC #2 EFFECT PRESSU RV SBL % SOLIDS CHIP METER SPEED 58% BL STORAGE LEVEL #4 EFFECT VAPOUR SBL TEMP PRESS -S 70% BL-STORAGE TANK #1 LEVEL #1 EFFECT RECIRC PUMP LOAD #5 EFFECT LEVEL MCC EA TREND DATA #3 EFFECT VAP COMBINED CONDENSATE CONDUCTIVITY 70% BL STORAGE TANK MASS FLOW BL SOLIDS TO EVAPS WBL #2 STORAGE LEVEL STRIPPED CONDENSATE TO RECAUST TANK#1 TMPERING WATER FLOW TO SURFACE CNDENSER EVAPORATION WBL FLOW ACROSS TO WEAK EFF L #2 EFF TRANSFER PUMP LOAD -0.2 IV TOTAL EA TO WOOD STEAM TEMP -#1 EFFECT 70% FLASH TANK VAPOUR PRESSURE STEAM PRESSURE TO EVAPS KAPPA # MANUAL VALVE STEAM-#1EFFECT STEAM FLOW TO #1 EFFECT III p[1] Steam Flow to 1 st Effect 31
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